Rockwell Automation

1606-XLE80E 24V, 3.3A; Single Phase Input

1606-XLE80E
24V,3.3A Single Phase Input
POWER SUPPLY
¾ Ultra-small size
¾ Extra-low inrush current
¾ Active power factor correction
¾ Wide range AC/DC input
¾ Superior efficiency and temperature rating
¾ DC-OK

1. GENERAL DESCRIPTION
The 1606 XLE power suppliesare cost optimized power supplies without compromising quality, reliability and performance. The 1606-XLE80E is part of
the XLE power supply family.
The 1606-XLE includes all the essential basic functions. The most important features are the small size, the high efficiency and the wide temperature
range.The wide-range-input makes worldwide installation and usage very simple.

2. SPECIFICATION QUICK REFERENCE

Output voltage DC 24V
Adjustment range
Output current
24 - 28V
3.3A At 24Vdc
3. AGENCY APPROVALS
2.7A At 28Vdc
Output power 80W IND. CONT. EQ.
UL 60950-1
Output ripple < 50mVpp 20Hz to 20MHz UL 508
Input voltage AC 100-240V Wide-range Input
Line frequency 50-60Hz ±6%
AC Input current typ. 1.24 / 0.68A At 120 / 230Vac
Power factor typ. 0.61 / 0.56 At 120 / 230Vac EMC, LVD
AC Inrush current typ. 23 / 45A At 120 / 230Vac
DC Input 110-375Vdc Full output current
88-110Vdc Output current max.
2.5A
Efficiency
Losses
typ. 88.0 / 89.8%
typ. 11.1 / 9.1W
At 120 / 230Vac
At 120 / 230Vac
4. RELATED PRODUCTS
1606-XLB Wall mount bracket
Temperature range -25°C to +70°C Operational 1606-XLSRED Redundancy Module
Derating 1.8W/°C +60 to +70°C 1606-XLBUFFER Buffer unit
Hold-up time typ. 29 / 120ms At 120 / 230Vac
Dimensions 32x124x102mm WxHxD

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1606-XLE80E 24V, 3.3A; Single Phase Input

INDEX PAGE INDEX PAGE

1. General Description................................................................1 21. Fulfilled Standards ................................................................14
2. Specification Quick reference.................................................1 22. Used Substances..................................................................15
3. Agency Approvals...................................................................1 23. Physical Dimensions and Weight .........................................15
4. Related Products ....................................................................1 24. Installation and Operation Instructions .................................16
5. AC-Input..................................................................................3 25. Accessory .............................................................................16
6. DC-Input .................................................................................4 26. Application Notes..................................................................17
7. Input Inrush Current Surge .....................................................5 26.1. Peak Current Capability ...........................................17
8. Hold-up Time ..........................................................................5 26.2. Charging of Batteries................................................17
9. Output.....................................................................................6 26.3. Back-feeding Loads..................................................17
10. Efficiency and Power Losses..................................................7 26.4. Output Circuit Breakers............................................18
11. Functional Diagram ................................................................8 26.5. Inductive and Capacitive Loads ...............................18
12. Reliability ................................................................................8 26.6. Series Operation ......................................................19
13. Product Face Label ................................................................9 26.7. Parallel Use to Increase Output Power ....................19
14. Terminals and Wiring............................................................10 26.8. Parallel Use for 1+1 Redundancy ............................19
15. EMC......................................................................................11 26.9. External Input Protection..........................................19
16. Environment .........................................................................12 26.10. Operation on Two Phases........................................20
17. Protection Features ..............................................................12 26.11. Use in a Tightly Sealed Enclosure ...........................20
18. Safety....................................................................................13 26.12. Mounting Orientations ..............................................21
19. Dielectric Strength ................................................................13
20. Approvals..............................................................................14

INTENDED USE
Those responsible for the application and use of the products must satisfy themselves that all necessary steps have been taken to assure that each
application and use meets all performance and safety requirements, including and applicable laws, regulation , codes, and standards.

TERMINOLOGY AND ABREVIATIONS

PE and symbol PE is the abbreviation for Protective Earth and has the same meaning as the symbol .
Earth, Ground This document uses the term “earth” which is the same as the U.S. term “ground”.
T.b.d. To be defined, value or description will follow later.
AC 230V A figure displayed with the AC or DC before the value represents a nominal voltage with standard tolerances (usually
±20%) included.
E.g.: DC 12V describes a 12V battery disregarding whether it is charged (13.7V) or discharged (10V). As long as not
otherwise stated, AC 100V and AC 230V parameters are valid at 50Hz and AC 120V parameters are valid at 60Hz
mains frequency.
230Vac A figure with the unit (Vac) at the end is a momentary figure without any additional tolerances included.

50Hz vs. 60Hz As long as not otherwise stated, AC 380V and AC 400V parameters are valid at 50Hz and AC 480V
parameters are valid at 60Hz mains frequency.
PELV Protective Extra Low Voltage
SELV Safety Extra Low Voltage

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
5. AC-INPUT
AC input nom. AC 100-240V Wide-range- input, see Fig. 5-1
AC input range 90-264Vac 100-120V range, continuous operation
85-90Vac Short term or with output derating
264-300Vac < 0.5s
Input frequency nom. 50 – 60Hz ±6%

AC 100V AC 120V AC 230V

Input current typ. 1.5A 1.24A 0.68A At 24V, 3.3A see Fig. 5-3
Power factor * typ. 0.62 0.61 0.56 At 24V, 3.3A see Fig. 5-1
Crest factor ** typ. 3.1 3.2 4.0 At 24V, 3.3A
Start-up delay typ. 95ms 95ms 95ms See Fig. 5-2
Rise time typ. 18ms 29ms 56ms 0mF, 24V, 3.3A, see Fig. 5-2
typ. 35ms 52ms 52ms 3.3mF, 24V, 3.3A, see Fig. 5-2
Turn-on overshoot max. 400mV 400mV 400mV See Fig. 5-2
Turn-on voltage typ. 75Vac 75Vac 75Vac Steady-state value, see Fig. 5-1
Shut-down voltage typ. 58Vac 58Vac 58Vac Steady-state value, see Fig. 5-1
* The power factor is the ratio of the true (or real) power to the apparent power in an AC circuit.
** The crest factor is the mathematical ratio of the peak value to the RMS value of the input current waveform

Fig. 5-1 Input voltage range Fig. 5-2 Turn-on behavior, definitions
Rated
POUT input range max. Intput
500ms Voltage
Shut -dow n

Turn-on

Output - 5%
Overshoot
Voltage
VIN Start-up Rise
delay Time
58 75 90 264 300Vac

Fig. 5-3 Input current vs. output load Fig. 5-4 Power factor vs. output load
Power
1.8A Input 0.65 Factor, typ.
Current, typ. (a)
1.5 (a) 0.60 (b)

1.2 (a) 100Vac (b) (c)

(b) 120Vac 0.55
0.9 (c) 230Vac
(c) 0.50 (a) 100Vac
0.6 (b) 120Vac
0.45 (c) 230Vac
0.3
Output Current Output Current
0 0.40
0.5 1.0 1.5 2.0 2.5 3.0 3.5A 0.5 1.0 1.5 2.0 2.5 3.0 3.5A

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
6. DC-INPUT
DC input nom. DC 110-300V
DC input range min. 88-375Vdc Continuous operation
DC input current typ. 0.81A / 0.29A 110Vdc / 300Vdc, 24V, 3.3A
Output current max. 2.5A At 24V and an input voltage between 88-110Vdc,
see Fig. 6-2
max. 3.3A At 24V and an input voltage between 110-375Vdc
Turn-on voltage typ. 103Vdc Steady-state value at 2.5A output load
Shut-down voltage typ. 50Vdc Steady-state value at 2.5A output load

Instructions for DC use:

a) Use a battery or similar DC source.
b) Connect + pole to L and – pole to N.
c) Connect the PE terminal to a earth wire or to the machine ground.
In case the – pole of the battery is not connected to earth, use an appropriate fuse to protect the N terminal.

Fig. 6-1 Wiring for DC input Fig. 6-2 Output current versus input voltage, max.

Output
Battery Current
Power Supply
3.5A
+ AC
internal
3.0
L
fused 2.5
+ 2.0
N Load 1.5
-
Fuse

PE 1.0
0.5
- DC DC Input Voltage
0
88 110 375Vdc

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
7. INPUT INRUSH CURRENT SURGE
A NTC limits the input inrush current after turn-on of the input voltage. The charging current into EMI suppression capacitors is disregarded in the first
microseconds after switch-on.

AC 100V AC 120V AC 230V

Inrush current max. 24Apeak 28Apeak 54Apeak At 40°C cold-start
typ. 20Apeak 23Apeak 45Apeak At 40°C cold-start
Inrush energy typ. 0.4A2s 0.5A2s 1.7A2s At 40°C cold-start

Fig. 7-1 Input inrush current, typical behavior

A: Start-up delay = Inrush delay

Input Current
Input: 230Vac
Output: 24V, 3.3A
Ambient: 25°C
Input Voltage
Upper curve: Input current 20A / DIV
Medium curve: Input voltage 500V / DIV
Lower curve: Output voltage 20V / DIV
Output Voltage Time scale: 40ms / DIV

8. HOLD-UP TIME
AC 100V AC 120V AC 230V
Hold-up Time typ. 38ms 60ms 244ms 1.65A, 24V, see Fig. 8-1
typ. 19ms 29ms 120ms 3.3A, 24V, see Fig. 8-1

Fig. 8-1 Hold-up time vs. input voltage Fig. 8-2 Shut-down behavior, definitions

225ms Hold-up
Time Zero Transition
200
24V, 1.65A, min. Intput
175
24V, 1.65A, typ. Voltage
150
125
100
75 - 5%
Output
50 24V, 3.3A, min.
Voltage
24V, 3.3A, typ.
25 Hold-up Time
Input Voltage
0
85 120 155 190 230Vac

Note: At no load, the hold-up time can be up to several seconds. The green DC-ok lamp is on during this time.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
9. OUTPUT
Output voltage nom. 24V
Adjustment range min. 24-28V Guaranteed
max. 30V At clockwise end position of potentiometer
Factory setting 24.1V ±0.2%, at full load, cold unit
Line regulation max. 50mV 90 to 264Vac
Load regulation max. 100mV Static value, 0A Æ 3.3A Æ 0A
Ripple and noise voltage max. 50mVpp 20Hz to 20MHz, 50Ohm
Output capacitance typ. 1 450µF
Output current nom. 3.3A At 24V, see Fig. 9-1
nom. 2.7A At 28V, see Fig. 9-1
Output power nom. 80W
Short-circuit current min. 4A Load impedance 250mOhm, see Fig. 9-1
max. 8A Load impedance 250mOhm, see Fig. 9-1

Fig. 9-1 Output voltage vs. output current, typ.

Output Voltage Adjustment

Range
28V
a) 100Vac
24 b) 120Vac
c) 230Vac
20
16
c b a
12
8
4
Output Current
0
0 1 2 3 4 5 6 7A

Peak current capability (up to several ms)

The power supply can deliver a peak current which is higher than the specified short term current. This helps to start current demanding loads or to
safely operate subsequent circuit breakers.
The extra current is supplied by the output capacitors inside the power supply. During this event, the capacitors will be discharged and causes a voltage
dip on the output. Detailed curves can be found in chapter 26.1.
Peak current voltage dips typ. from 24V to 12.5V At 6.6A for 50ms, resistive load
typ. from 24V to 12.5V At 16.5A for 2ms, resistive load
typ. from 24V to 7V At 16.5A for 5ms, resistive load

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
10. EFFICIENCY AND POWER LOSSES
AC 100V AC 120V AC 230V
Efficiency typ. 86.4% 88.0% 89.8% 3.3A, 24V
Power losses typ. 1W 1.1W 1.8W 0A
typ. 5.4W 4.9W 5.9W 1.65A, 24V
typ. 12.5W 11.1W 9.1W 3.3A, 24V

Fig. 10-1 Efficiency vs. output current at 24V, typ. Fig. 10-2 Losses vs. output current at 24V, typ.

Efficiency a) 100Vac Power Losses

91% b) 120Vac 12W
a
c) 230Vac b
90 a) 100Vac
c 10 b) 120Vac
c) 230Vac c
89 8
88 6
b
87 4
a
86 2
Output Current Output Current
85 0
0.5 1.0 1.5 2.0 2.5 3.0 3.5A 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5A

Fig. 10-3 Efficiency vs. input voltage, 24V, 3.3A, typ. Fig. 10-4 Losses vs. input voltage, 24V, 3.3A, typ.
Efficiency Power Losses
91% 18W
90 15
89 12
88 9
87 6
86 3
Input Voltage Input Voltage
85 0
85 120 155 190 225 260Vac 85 120 155 190 225 260Vac

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
11. FUNCTIONAL DIAGRAM
Fig. 11-1 Functional diagram

Output
Voltage
Regulator VOUT

L Input +
Input Fuse Rectifier Power Output +
N & & Converter Filter
Input Filter NTC Inrush -
Limiter
-
Output
Over- DC
Voltage ok
Protection

12. RELIABILITY
These units are extremely reliable and use only the highest quality materials. The number of critical components such as electrolytic capacitors has
been reduced.
AC 100V AC 120V AC 230V
Lifetime expectancy min. 57 000h 64 000h 77 000h 40°C, 24V, 3.3A
min. t.b.d. t.b.d. t.b.d. 40°C, 24V, 1.65A
min. 160 000h >15 years >15 years 25°C, 24V, 3.3A
MTBF SN 29500, IEC 61709 t.b.d. t.b.d. t.b.d. 40°C, 24V, 3.3A
t.b.d. t.b.d. t.b.d. 25°C, 24V, 3.3A
MTBF MIL HDBK 217F t.b.d. t.b.d. t.b.d. 40°C, 24V, 3.3A, Ground Benign GB40
t.b.d. t.b.d. t.b.d. 25°C, 24V, 3.3A, Ground Benign GB25

The Lifetime expectancy shown in the table indicates the operating hours (service life) and is determined by the lifetime expectancy of the built-in
electrolytic capacitors.
Lifetime expectancy is specified in operational hours. Lifetime expectancy is calculated according to the capacitor’s manufacturer specification. The
prediction model allows a calculation of up to 15 years from date of shipment.
MTBF stands for Mean Time Between Failure, which is calculated according to statistical device failures, and indicates reliability of a device. It is the
statistical representation of the likelihood of a unit to fail and does not necessarily represent the life of a product.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
13. PRODUCT FACE LABEL
Fig. 13-1 Front side

Output Terminals Output voltage potentiometer

Screw terminals Open the flap to tune the output voltage.
Factory set: 24.1V
+ Positive output
- Negative (return) output
Dual pins per pole
DC-on lamp (green)
On when the voltage at the output terminals
is > 21 V

Input Terminals
Screw terminals
N … Neutral input
L … Line (hot) input
... PE (Protective Earth) input

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
14. TERMINALS AND WIRING
All terminals are easy to access when mounted on the panel. Input and output terminals are separated from each other (input below, output above) to
help in error-free wiring.
Type Screw terminals
Solid wire 0.5-6mm2
Stranded wire 0.5-4mm2
American wire gauge 20-10 AWG
Ferrules Allowed, but not required
Wire stripping length 7mm / 0.275inch
Screwdriver 3.5mm slotted or Pozidrive No 2
Recommended tightening torque 0.8Nm, 7lb.in
Instructions:
a) Use appropriate copper cables that are designed for an operating temperature of:
60°C for ambient up to 45°C and 75°C for ambient up to 60°C minimum.
b) Follow national installation codes and installation regulations!
c) Ensure that all strands of a stranded wire enter the terminal connection!
d) Up to two stranded wires with the same cross section are permitted in one connection point (except PE wire).
e) Do not use the unit without PE connection.
f) In order to fulfill GL requirements, unused terminal spaces must be closed.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input

15. EMC
The CE mark is in conformance with EMC directive 89/336/EC, 93/68/EC and 2004/108/EC and the low-voltage directive (LVD) 73/23/EWG.

EMC Immunity EN 61000-6-2, EN 61000-6-1 Generic standards

Electrostatic discharge EN 61000-4-2 Contact discharge 8kV Criterion A
Air discharge 15kV Criterion A
Electromagnetic RF field EN 61000-4-3 80MHz-2.7GHz 10V/m Criterion A
Fast transients (Burst) EN 61000-4-4 Input lines 4kV Criterion A
Output lines 2kV Criterion A
Surge voltage on input EN 61000-4-5 LÆN 2kV Criterion A
N / L Æ PE 4kV Criterion A
Surge voltage on output EN 61000-4-5 +Æ- 500V Criterion A
+ / - Æ PE 500V Criterion A
Conducted disturbance EN 61000-4-6 0,15-80MHz 10V Criterion A
Mains voltage dips EN 61000-4-11 0% of 100Vac 0Vac, 20ms Criterion B *)
40% of 100Vac 40Vac, 200ms Criterion C
70% of 100Vac 70Vac, 500ms Criterion A
0% of 200Vac 0Vac, 20ms Criterion A
40% of 200Vac 80Vac, 200ms Criterion A
70% of 200Vac 140Vac, 500ms Criterion A
Voltage interruptions EN 61000-4-11 0Vac, 5000ms Criterion C
Input voltage swells RA internal standard 300Vac, 500ms Criterion A
Powerful transients VDE 0160 Over entire load range 750V, 1.3ms Criterion A
Criterions:
A: Power supply shows normal operation behavior within the defined limits.
B: The power supply continuous to operate as intended after the test. No degradation of performance or loss of function occur,
when the power supply is used as intended. During the test, degradation of performance is however possible.
C: Temporary loss of function is possible. Power supply might shut-down and restarts by itself. No damages or hazards for the
power supply will occur.
*) Below 2.8A criterion A is fulfilled

EMC Emission EN 61000-6-3, EN 61000-6-4 Generic standards

Conducted emission EN 55011, EN 55022, FCC Part 15, CISPR 11, CISPR 22 Class B, input lines
EN 55022 Class A, output lines
Radiated emission EN 55011, EN 55022 Class B
Harmonic input current EN 61000-3-2 Fulfilled (Class A)
Voltage fluctuations, flicker EN 61000-3-3 Fulfilled
This device complies with FCC Part 15 rules.
Operation is subjected to following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference
received, including interference that may cause undesired operation.

Switching frequency
50kHz to 450kHz Input voltage and load dependent

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1606-XLE80E-2 24V, 3.3A; Single Phase Input

16. ENVIRONMENT
Operational temperature -25°C to +70°C (-13°F to 158°F) Resistive load,
Reduce output power according Fig. 16-1
Output de-rating 1.8W/°C 60-70°C (140°F to 158°F)
Storage temperature -40 to +85°C (-40°F to 185°F) Storage and transportation
Humidity 5 to 95% r.H. IEC 60068-2-30
Do not energize while condensation is present
Vibration sinusoidal 2-17.8Hz: ±1.6mm; 17.8-500Hz: 2g IEC 60068-2-6
2 hours / axis
Shock 30g 6ms, 20g 11ms IEC 60068-2-27
3 bumps / direction, 18 bumps in total
Altitude 0 to 6000m (0 to 20 000ft) Reduce output power or ambient temperature above
2000m sea level.
Output de-rating (for altitude) 5W/1000m or 5°C/1000m above 2000m (6500ft), see Fig. 16-2
Over-voltage category III EN 50178, IEC 62103 altitudes < 2000m
II Altitudes from 2000m to 6000m
Degree of pollution 2 EN 50178, IEC 62103 not conductive

Fig. 16-1 Output current vs. ambient temp., Fig. 16-2 Output current vs. altitude, 24V

Allowable Output Allowable Output

Current at 24V Current at 24V
4A 4A
C
3 3 B
A
2 2

1 1 A... Tamb < 60°C

B... Tamb < 50°C
Ambient Temperature C... Tamb < 40°C Altitude
0 0
-25 0 20 40 60 70°C 0 2000 4000 6000m

The ambient temperature is defined 2cm below the unit.

17. PROTECTION FEATURES

Output protection Electronically protected against overload, no-load and short-circuits
Output over-voltage protection typ. 34Vdc In case of an internal power supply defect, a redundant circuitry limits
max. 39Vdc the maximum output voltage. The output shuts down and automatically
attempts to restart.
Output over-current protection electronically limited See Fig. 9-1
Degree of protection IP 20 EN/IEC 60529
Penetration protection > 3.5mm E.g. screws, small parts
Over-temperature protection no
Input transient protection MOV Metal Oxide Varistor
Internal input fuse T6.3A H.B.C. Not user replaceable
Note: In case of a over-voltage, overload, no-load or short-circuit event, an audible noise may be heard.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
18. SAFETY
Input / output separation SELV IEC/EN 60950-1
PELV EN 60204-1, EN 50178, IEC 62103, IEC 60364-4-41
double or reinforced insulation
Class of protection I PE (Protective Earth) connection required
Isolation resistance > 5MOhm input to output, 500Vdc
PE resistance < 0.1Ohm between housing and PE terminal
Touch current (leakage current) typ. 0.16mA 100Vac, 50Hz
typ. 0.24mA 120Vac, 60Hz
typ. 0.41mA 230Vac, 50Hz
< 0.22mA 110Vac, 50Hz
< 0.32mA 132Vac, 60Hz
< 0.57mA 264Vac, 50Hz

19. DIELECTRIC STRENGTH

To fulfill the PELV requirements according to EN60204-1 § 6.4.1, we recommend that either the + pole, the – pole or any other part of the output circuit
shall be connected to the protective earth system. This helps to avoid situations in which a load starts unexpectedly or can not be switched off when
unnoticed earth faults occur.

Fig. 19-1 Dielectric strength A B C

Input Type test 60s 2500Vac 3000Vac 500Vac
L Factory test 5s 2500Vac 2500Vac 500Vac
N B
Field test 5s 2000Vac 2000Vac 500Vac
Output
A + Type tests and factory tests:
C
- Conducted by the manufacturer. Do not repeat test in field!
Earth, PE Rules for field test:
Use appropriate test equipment which applies the voltage with a slow ramp!
Connect L and N together as well as all output poles.

The output voltage is floating and has no ohmic connection to ground.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
20. APPROVALS

IECEE
IEC 60950-1 CB Scheme,
Information Technology Equipment
CB SCHEME
UL 508 18WM LISTED E198865
LISTED Industrial Control Equipment
IND. CONT. EQ.

NEC Class 2 According to NEC (National Electrical Code) Article 725-41 (4).
Listed as Limited Power Source (LPS) in the UL 60950-1 UL report.
UL 60950-1 RECOGNIZED E137006 recognized for the use in U.S.A. (UL 60950-1) and Canada
(C22.2 No. 60950)
Information Technology Equipment, Level 3
CSA CSA approval for Canada
pending R
CAN/CSA C22.2 No 107-1; CAN/ CSA 60950-1-03; UL60950-1
C US
182790

21. FULFILLED STANDARDS

EN 61558-2-17 Safety of Power Transformers
EN/IEC 60204-1 Safety of Electrical Equipment of Machines
EN/IEC 61131-2 Programmable Controllers
EN 50178, IEC 62103 Electronic Equipment in Power Installations

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
22. USED SUBSTANCES
The unit does not release any silicone and is suitable for the use in paint shops.
The unit conforms to the RoHS directive 2002/96/EC
Electrolytic capacitors included in this unit do not use electrolytes such as Quaternary Ammonium Salt Systems.
Plastic housings and other molded plastic materials are free of halogens, wires and cables are not PVC insulated.
The production material within our production does not include following toxic chemicals:
Polychlorized Biphenyl (PCB), Polychlorized Terphenyl (PCB), Pentachlorophenol (PCP), Polychlorinated naphthalene (PCN), Polybrom Biphenyl (PBB),
Polybrom Bipheny-oxyd (PBO), Polybrominated Diphenylether (PBDE), Polychlorinated Diphenylether (PCDE), Polydibromphenyl Oxyd (PBDO),
Cadmium, Asbest, Mercury, Silicia

23. PHYSICAL DIMENSIONS AND WEIGHT

Weight 430g / 0.95lb
DIN-Rail Use 35mm DIN-rails according to EN 60715 or EN 50022 with a height of 7.5 or 15mm.
The DIN-rail height must be added to the depth (102mm) to calculate the total required installation depth.
Electronic files can be downloaded at www.ab.com

Fig. 23-1 Front view Fig. 23-2 Side view

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
24. INSTALLATION AND OPERATION INSTRUCTIONS

Hazardous voltage inside device. Risk of electric shock, severe burns, or death.
• Do not use the unit without proper earth connection (Protective Earth). Use the pin on the terminal block for earth connection and not one of
the screws on the housing.
• Turn power off before working on the power supply. Protect against inadvertent re-powering.
• Make sure the wiring is correct by following all local and national codes.
• Do not open, modify or repair the unit.
• Use caution to prevent any foreign objects from entering into the housing.
• Do not use in wet locations or in areas where moisture or condensation can be expected.

Mounting Orientation:
Output terminal must be located on top and input terminal on the bottom. For other orientations see section 26.12
Cooling:
Convection cooled, no forced cooling required. Do not cover ventilation grid (e.g. cable conduits) by more than 30%!
Installation clearances:
40mm on top, 20mm on the bottom, 5mm on the left and right side are recommended when loaded permanently with full power. In case the adjacent
device is a heat source, 15mm clearance is recommended.
Service parts:
The unit does not contain any serviceable parts. The tripping of an internal fuse is caused by an internal defect.

25. ACCESSORY
1606-XLB Wall mounting bracket
This bracket is used to mount XLE units onto a flat surface without utilizing a DIN-Rail. The two aluminum brackets and the black plastic slider of the
unit have to be detached, so that the two steel brackets can be mounted.
(Picture shows a different power supply)
Fig. 25-1 1606-XLB Wall Mounting Bracket Fig. 25-2 Assembled Wall Mounting Bracket

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
26. APPLICATION NOTES

26.1. PEAK CURRENT CAPABILITY

Solenoids, contactors and pneumatic modules often have a steady state coil and a pick-up coil. The inrush current demand of the pick-up coil is several
times higher than the steady state current and usually exceeds the nominal output current (including the PowerBoost) The same situation applies, when
starting a capacitive load.
Branch circuits are often protected with circuit breakers or fuses. In case of a short or an overload in the branch circuit, the protective device needs a
certain amount of over-current to trip or to blow. The peak current capability ensures the safe operation of subsequent circuit breakers.
Assuming the input voltage is turned on before such an event, the built-in large sized output capacitors inside the power supply can deliver extra
current. Discharging this capacitor causes a voltage dip on the output. The following two examples show typical voltage dips:
Fig. 26-1 Peak load 6.6A for 50ms, typ. Fig. 26-2 Peak load 16.5A for 5ms, typ.

Output Output
Voltage 24V Voltage 24V

6.6A 16.5A
12.5V

7V
Output Output
Current Current
0A 0A
10ms/DIV 1ms/DIV

Peak load 6.6A (resistive) for 50ms Peak load 16.5A (resistive) for 5ms
Output voltage dips from 24V to 12.5V. Output voltage dips from 24V to 7V.

26.2. CHARGING OF BATTERIES

The power supply shall not be used to charge batteries.

26.3. BACK-FEEDING LOADS

Loads such as decelerating motors and inductors can feed voltage back to the power supply. This feature is also called return voltage immunity or
resistance against Back- E.M.F. (Electro Magnetic Force).
This power supply is resistant and does not show malfunctioning when a load feeds back voltage to the power supply. It does not matter, whether the
power supply is on or off.
The maximum allowed feed back voltage is 35Vdc. The absorbing energy can be calculated according to the built-in large sized output capacitor which
is specified in chapter 9.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input

26.4. OUTPUT CIRCUIT BREAKERS

Standard miniature circuit breakers (MCBs) can be used for branch protection. Ensure that the MCB is rated for DC voltage, too. The following tests
show which circuit breakers the power supply typically trips.
Circuit breakers have large tolerances in their tripping behavior. Therefore, these typical tests can only be used as a recommendation or for comparing
two different power supplies. Furthermore, the loop impedance has a major influence on whether a breaker trips or not. Two tests were performed,
representing typical situations:

Test 1: Short circuit with S1 on the power supply end of the cable (loop impedance approx. 20mOhm)
Fig. 26-3 Branch protectors, test circuit 1

Parameters:
Circuit
Breaker
Input voltage: 230Vac, load current: 0A
Power
Supply I
AC + + The following circuit breaker tripped during the test:
S1 Load
A- or Z- Characteristic:: equal or smaller 6A
B- Characteristic: no tripping ≥ 6A
DC - - no breaker available < 6A
C- Characteristic: equal or smaller 1A

Test 2: Short circuit with S1 on the load end (additional impedance included; represents longer load wire length).
Fig. 26-4 Branch protectors, test circuit 2 Parameters:
Input voltage: 230Vac, load current: 0A
Circuit
Power Breaker The following circuit breaker tripped during the test:
Supply I
R A- or Z- Characteristic:: ≤ 4A and R= 220mOhm
AC + + B- Characteristic: no tripping ≥ 6A
S1 Load no breaker available < 6A
C- Characteristic: ≤ 1A and R= 390mOhm
DC - -

What does this resistance mean in wire length?

0.5mm2 0.7mm2 1.0mm2 1.5mm2 2.5mm2 4.0mm2
220mOhm 6.1m 8.6m 12.3m 18.4m 30.6m 49m
390mOhm 10.9m 15.2m 21.7m 32.6m 54.3m 86.9m

Example:
Which wire gauge must be used to trip a C-Characteristic circuit breaker with a rating of 1A? The load wire length is 25m.
Answer: A 1A C-Characteristic circuit breaker requires a loop impedance of less than 390mOhm (test results). The wire length table shows that up to
32.6m wire with a cross section of 1.5mm2 are below 390mOhm. A wire not smaller than 1.5mm2 shall be used.

26.5. INDUCTIVE AND CAPACITIVE LOADS

The unit is designed to supply any type of load, including unlimited capacitive and inductive loads.

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
26.6. SERIES OPERATION
The power supply can be put in series to increase the output voltage.
Fig. 26-5 Schematic for series operation Instructions for use in series:
a) It is possible to connect as many units in series as needed, providing the sum
Unit A of the output voltage does not exceed 150Vdc.
AC b) Warning ! Voltages with a potential above 60Vdc are not SELV any more and
+ can be dangerous. Such voltages must be installed with a protection against
- touching.
DC c) For serial operation use power supplies of the same type.
+ d) Earthing of the output is required when the sum of the output voltage is above
Unit B
Load 60Vdc.
AC
+ - e) Keep an installation clearance of 15mm (left/right) between two power supplies
and avoid installing the power supplies on top of each other.
- Earth
DC Note: Avoid return voltage (e.g. from a decelerating motor or battery) which is
applied to the output terminals.

26.7. PARALLEL USE TO INCREASE OUTPUT POWER

The power supply shall not be used in parallel to increase the output power.

26.8. PARALLEL USE FOR 1+1 REDUNDANCY

Power supplies can be paralleled for 1+1 redundancy to gain a higher system reliability. Redundant systems require a certain amount of extra power to
support the load in case one power supply unit fails. The simplest way is to put two 1606-XLE power supplies in parallel. In case one power supply unit
fails, the other one is automatically able to support the load current without any interruption. This simple way to build a redundant system has two major
disadvantages:
a. The faulty power supply can not be recognized. The green LED will still be on since it is reverse-powered from the other power supply.
b. It does not cover failures such as an internal short circuit in the secondary side of the power supply. In such a - situation the defective unit
becomes a load for the other power supplies and the output voltage can not be maintained any more.
This above conditions can be avoided by utilizing decoupling diodes which are included in the decoupling module 1606-XLSRED or redundancy module
1606-XLERED.
Other recommendations for building redundant power systems:
a) Use separate input fuses for each power supply.
b) Monitor the individual power supply units. A DC-ok lamp and a DC-ok contact is included in the redundancy module 1606-XLERED. This feature
reports a faulty unit.
c) When possible, connect each power supply to different phases or circuits.

26.9. EXTERNAL INPUT PROTECTION

The unit is tested and approved for branch circuits up to 20A. External protection is only required if the supplying branch has an ampacity greater than
this. In some countries local regulations might apply. Check also local codes and requirements.
If an external protective device is utilized, a minimum value is required to avoid undesired tripping of the fuse.
B-Characteristic C-Characteristic
Ampacity max. 20A 20A
min. 10A 6A

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1606-XLE80E-2 24V, 3.3A; Single Phase Input
26.10. OPERATION ON TWO PHASES
Fig. 26-6 Schematic for two phase operation

Power Supply Instructions for two phase operation:

L1 AC a) A phase to phase connection is allowed as long as the supplying voltage is
below 240V+10%.
max.

internal
fuse
L b) Use a fuse or a circuit breaker to protect the N input. The N input is
internally not protected and is in this case connected to a hot wire.
+10%

Fuse
L3 N
Appropriate fuses or circuit breakers are specified in section 26.9 “External Input
240V

PE
Protection”.
L2 DC

26.11. USE IN A TIGHTLY SEALED ENCLOSURE

When the power supply is installed in a tightly sealed enclosure, the temperature inside the enclosure will be higher than outside. The inside
temperature defines the ambient temperature for the power supply.
Results from such an installation:
Power supply is placed in the middle of the box, no other heat producer inside the box
Enclosure: Type IP66 Box PK 9516 100, plastic, 110x180x165mm
Input: 230Vac

Load: 24V, 3.3A; load is placed outside the box

Temperature inside the box: 45.7°C (in the middle of the right side of the power supply with a distance of 1cm)
Temperature outside the box: 27.3°C
Temperature rise: 18.4K
Load: 24V, 2.64A; (=80%) load is placed outside the box
Temperature inside the box: 41.8°C (in the middle of the right side of the power supply with a distance of 1cm)
Temperature outside the box: 26.5°C
Temperature rise: 15.3K

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1606-XLE80E-2 24V, 3.3A; Single Phase Input

26.12. MOUNTING ORIENTATIONS

Mounting orientations other than input terminals on the bottom and output on the top require a reduction in continuous output power or a limitation in the
max. allowed ambient temperature. The amount of reduction influences the lifetime expectancy of the power supply. Therefore, two different derating
curves for continuous operation can be found below:
Curve A1 Recommended output current.
Curve A2 Max allowed output current (results approx. in half the lifetime expectancy of A1).
Fig. 26-7 Mounting Output Current
Orientation A OUTPUT 4A
Standard Orientation A1
3
Power
Supply 2
1
Ambient Temperature
INPUT 0
10 20 30 40 50 60°C

Fig. 26-8 Output Current

Mounting Orientation INPUT
4A
B A2
(Upside down) 3
Supply A1
Power 2
1
Ambient Temperature
0
OUTPUT

10 20 30 40 50 60°C

Fig. 26-9 Mounting Output Current

Orientation C 4A
(Table-top mounting) A2
3
A1
2
1
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 26-10 Mounting Output Current

Orientation D 4A
(Horizontal cw) A2
3
OUTPUT
Supply
Power

A1
INPUT

2
1
Ambient Temperature
0
10 20 30 40 50 60°C

Fig. 26-11 Mounting Output Current

Orientation E 4A
(Horizontal ccw)
A2
3
OUTPUT

Supply
Power

INPUT

A1
2
1
Ambient Temperature
0
10 20 30 40 50 60°C

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